Things You'll Need
- 6 boards -- 1 by 2 inches, 6 feet long
- 1 board -- 1 by 2 inches, 45 inches long
- 13 boards -- 1 by 2 inches, 22.5 inches long
- 2 boards -- 1 by 2 inches, 36 inches long
- 2 boards -- 1 by 2 inches, 38 inches long
- 2 boards -- 1 by 2 inches, 34 inches long
- 1/2-inch wooden pins
- Nontoxic wood glue
- Staple gun and staples
- Rolls of wire mesh
- Wire cutters
- Hammer
- Nails
- 2 brass butterfly hinge kits
- Screen door safety hook and eye
- Miter saw
- 2-inch wood screws
- Drill
Instructions
Use a miter saw to cut a 60-degree angle at the ends of all the 22.5-inch boards. The angle on these rail parts should go from front to back on the board.
Drill two 1/2-inch holes in the angle cut ends of the rails, with the holes 1 inch apart.
Drill two 1/2-inch holes holes 1 inch apart in the top 1-inch edges of the 6-foot-long uprights. Drill matching holes at the other end. The holes should align so that, when later connected, the top rail will align with the top of the upright and the bottom rail will align with the bottom of the upright.
Insert glue-coated wooden pins into the holes at the ends of the rails. Push the pins protruding from the rails into the matching holes in the uprights. You will have one upright and two rails for each of the six panels you are assembling. Let the glue dry.
Insert glue-coated wooden pins into the holes on the ends of the rails not connected to an upright. Push the pins protruding from the rails into the matching holes on the other side of the uprights. This connects the six panels to make the six-sided shape of the cage. Let the glue dry.
Drill two 1/2-inch holes 1 inch apart in the right 1-inch side of one of the uprights. The bottom hole should be 36 inches from the bottom. Drill matching holes in the left 1-inch side of the upright, just to the right of the first. Insert glued wooden pins into the holes.
Press the holes at one end of a rail onto one pair of the pins you just inserted. Push the other upright with pins back slightly to bow it, so you can press the holes at the other end of the rail onto those pins. This leaves a spot for the door. Let the glue dry.
Place the 45-inch long board flat on the top of the cage, so that each end is resting on opposite uprights. Use the drill to drive a wood screw through each end of the 45-inch board into the uprights. This board will act as a brace for the cage.
Place one of the 36-inch long boards between the bottom and middle rails of the door section, 2 inches from the upright on the left. Use the drill to drive screws into the middle and bottom rails, and into the 36-inch long board to hold it in place. Repeat this with the other 36-inch long board, placing it 2 inches from the upright on the right. This creates the door frame.
Cut six sections of wire mesh 74 by 38 inches, using wire cutters. Use a staple gun to attach them to the sides. Cut away the section of the mesh that overlaps where the door will go. Cut another piece of mesh 45 by 45 inches. Place this on the top and staple it to the cage. Trim off the excess. Ensure that any openings in the mesh have been closed with the stapler.
Cut the ends of the 38-inch long boards and the 34-inch long boards at a 45-degree angle with a miter saw. Place the 1-inch sides together to form a frame-like structure. Hammer nails through the ends of the 34-inch boards and into the ends of the 38-inch boards to connect them to make the door.
Cut a piece of mesh that is 38 by 34 inches. Staple it onto the door, again making sure there are no spaces the bird can escape through.
Use the screws that came with hinge kit to attach one hinge to the door, placing the hinge 1 inch down from the top-left side of the door. In the same way, place the other hinge at the bottom-left side of the door.
Position the door so it overlays the door frame, and screw the other halves of the butterfly hinges to the door frame. Screw the screen door safety hook into the right side of the door, near the middle. Move the hook to judge where you should place the screw-in eye. Screw in the eye and latch the door.